POWER POWER PRESS PRESS

OPERATOR OPERATOR TRAININGTRAINING

Robert N. Andres, CSP, CMfgE

OSHEX – ESA Consulting Services© RNA, 1999

POWER PRESSES …POWER PRESSES …Have a flywheelOperate by transferring energy from a

rotating flywheel to the ram (or slide) by means of a clutch

May be a “full-revolution” design, with a “trip” clutch engagement, or

May be a “part-revolution” design, with a friction clutch and brake

POWER PRESSES …POWER PRESSES …Are generally defined in “size” by the

force that they can generate – from under 5 ton to over 300 ton capacity

Have a variety of forms and styles. The most common are straight-sided and open-backed inclinable (OBI) styles.

Are addressed in detail in ANSI B11.1 and OSHA 29 CFR 1910.217

SAFE OPERATION OF A SAFE OPERATION OF A POWER PRESS DEPENDS POWER PRESS DEPENDS

UPON …UPON …The structural integrity of the machine

and it’s safeguards The reliability of the control systemThe condition of the tooling and feed

mechanisms, and the work areaYour training and awarenessStrict observance of safe work practice

THIRTY-EIGHT THIRTY-EIGHT STEPS THAT CAN STEPS THAT CAN

SAVE YOUR SAVE YOUR FINGERS, HANDS FINGERS, HANDS

OR YOUR LIFEOR YOUR LIFE

Safety is everyone’s responsibility !

THE WORK AREATHE WORK AREA

Can the metal be moved into the work area, still leaving enough room to get out ?

THE WORK AREA THE WORK AREA

What is the condition of the floor? Does it need repair? Report it!

PRESS INTEGRITYPRESS INTEGRITY

Have I checked the press completely before beginning my shift ?

Use your check list! Make sure that someone has not left something on the press, such as a turnover bar, blow-off hose or die block

PRESS INTEGRITYPRESS INTEGRITY

Are all the bolts tight?Are there any visible cracks?

PRESS INTEGRITY PRESS INTEGRITY

Are all the service lines (electrical, air, etc.) Properly connected and free of any damage. Report any deficiencies to your supervisor.

PRESS INTEGRITY PRESS INTEGRITY

Have I tested the clutch and brake operation before starting the main motor? Immediately after?

PRESS INTEGRITYPRESS INTEGRITYDoes the press continue to cycle

when the footswitch or palm buttons remain depressed? If so, it does not have required “single-stroke capability.”* Notify your supervisor immediately.

* Not required on presses when used in the continuous mode.

PRESS INTEGRITYPRESS INTEGRITY

Does the press cycle with only one palm button depressed, or with one continuously held down and the other depressed to start the cycle? If so, it does not have required “anti-tie-down circuitry.” Notify your supervisor immediately.

PRESS INTEGRITYPRESS INTEGRITYAre the operating controls

(mode selector, palm buttons, foot switch, top stop, emergency stop) in good working condition?

Is the “ground” fault detection lamp lit. Do not operate the press if light is not.

PRESS INTEGRITYPRESS INTEGRITY

Is all of the auxiliary equipment (roll feed, scrap chopper, blow off, etc.) In good working order?

PRESS ADJUSTMENTSPRESS ADJUSTMENTS

Have I checked all the knockout adjustments?

PRESS SAFEGUARDING PRESS SAFEGUARDING Does the

guard or device positively prevent body access into the danger zone?

POINT OF OPERATION GUARD OPENING REQUIREMENTS

Dist. from PO Max Open’g

1/2” to 1-1/2” 1/4”

1-1/2” to 2-1/2” 3/8”

2-1/2” to 3-1/2” 1/2”

3-1/2” to 5-1/2” 5/8”

5-1/2” to 6-1/2” 3/4”

6-1/2” to 7-1/2” 7/8”

PRESS SAFEGUARDINGPRESS SAFEGUARDING

Are the sides and back of the press guarded or placed in such a way that another person cannot be injured by any part of the machine?

PRESS SAFEGUARDINGPRESS SAFEGUARDING

Is the safety guard sturdy and secure? Does the safety device work properly?

PRESS SAFEGUARDING PRESS SAFEGUARDING

If I have a foot pedal, is it guarded on the top and sides?

Does it spring back when released?

THE POINT-OF-OPERATION THE POINT-OF-OPERATION

Is the die area clean? Have all slugs and debris been removed?

THE POINT-OF-OPERATION THE POINT-OF-OPERATION

Can the parts I feed be placed into the die easily, without causing damage to the parts, or any part of my body?

UNDERSTANDING RISKS UNDERSTANDING RISKS Do I truly understand the safe

operation of the press … or do I need more training?– Don’t be afraid to admit it !– Don’t be afraid to ask

“dumb” questions !

Your life could depend on it !

UNDERSTANDING RISKS UNDERSTANDING RISKS

Do I know the “tonnage” of the press and the requirement of the tooling? Do I know if the press is overloaded?

UNDERSTANDING RISKS UNDERSTANDING RISKS

Do I understand the maximum thickness or “gauge” and type of metal which the tooling and press can safely run?

PRESS IN OPERATIONPRESS IN OPERATION

Does the machine operate smoothly and sound O.K.?

Any squealing? Shuttering? Clicking? Clanking? Excess vibration?

PRESS IN OPERATION PRESS IN OPERATION

Does the die stripper work properly?

PRESS IN OPERATION PRESS IN OPERATION

Does the take-up reel work properly?

PRESS IN OPERATION PRESS IN OPERATION

In operation, does the die bind or jam? If so, notify your supervisor. The problem may be the tooling, the press, or the stock/part.

PRESS IN OPERATION PRESS IN OPERATION

Does the clutch/brake work properly. In the case of a full revolution press, does the drag brake stop the press at top center?

UNDERSTANDING RISKS UNDERSTANDING RISKS

What is the expected Noise Level? Do I need hearing protection?

READ AND HEED !READ AND HEED !

Never unnecessarily place your hands or any part of your body in the machine!

READ AND HEED !READ AND HEED !

Never operate this machine without proper eye, face and body protection!

READ AND HEED !READ AND HEED !

Never operate this machine without first being fully training and instructed!

READ AND HEED !READ AND HEED !

Never operate this machine without first reading the manufacturer’s instruction manual!

READ AND HEED !READ AND HEED !

Never operate this machine if it is not working properly! Stop operating and advise your supervisor immediately!

READ AND HEED !READ AND HEED !

Never use a foot switch to operate this machine unless a point-of-operation guard or device is provided and properly maintained!

READ AND HEED !READ AND HEED !

Never tamper with, rewire or bypass ANY control or component on the machine. Interlocks are provided for your safety. If they prevent proper operation, consult your supervisor immediately !

READ AND HEED !READ AND HEED !

Never operate this machine unless a supplied two-hand control or presence-sensing device is installed at a proper safety distance. Consult your supervisor if you have any questions.

ANY QUESTIONS?ANY QUESTIONS?

Talk to your plant Safety Supervisor, call OSHEX @ 1-888-MORE-SAFE, or e-mail info@oshex.com